United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
Research and Development
EPA/600/S2-87/060 Dec. 1 987
Project Summary
Novel Vapor-Deposited Lubricants
for Metal-Forming Processes
J. J. Mills
This report gives results of a labora-
tory study of the feasibility of using
vapor-phase lubrication to lubricate
industrial metal forging dies. It gives
results of six tasks conducted during
the study and discusses the potential
production and environmental impact
of the process. If a vapor lubrication
system can be developed for general
industrial use it can significantly reduce
the volume of forging lubricants required
by present industrial forging operations.
The laboratory results indicate that it
may be possible to reduce potential air
pollution emissions from forging using
vapor lubrication by as much as 85%.
This would be accomplished by using
85% less lubricant volume during metal
forging.
This Project Summary was developed
by EPA's Air and Energy Engineering
Research Laboratory, Research Triangle
Park, NC, to announce key findings of
the research project that Is fully docu-
mented In a separate report of the same
title (see Project Report ordering In-
formation at back).
Introduction
The forging and shaping of metal parts
is one of many metal fabricating pro-
cesses that may generate emissions of
volatile organic compounds (VOCs) and
hydrocarbons. In typical metal forming
operations hot metal is squeezed in dies
to produce metal shapes in the form of
the die cavity. This process may require
many intermediate forming and shaping
steps using successively more accurate
dies to reach the finished product. A key
aspect of these shaping steps is the
lubrication of the dies and metal parts to
allow easy release of the part from the
die. The used lubricants frequently result
in emissions containing VOCs and poten-
tially toxic metal to the atmosphere.
This report presents the results of a
Phase I study that investigated the feasi-
bility of using vapor-phase lubrication for
industrial metal forging dies. It presents
the results of six tasks conducted during
the study and discusses the potential
production and environmental impact of
the effectiveness of the process. A vapor
lubrication system developed for general
industrial use could significantly reduce
the volume of forging lubricants required
by present industrial forging operations.
The project proposes to use a vapor-
phase polymer film to lubricate forging
dies in their closed position. An injection
device allows lubricant vapor to be applied
automatically through passages in the
flange areas of the die. This eliminates
large volumes of liquid die lubricants and
the resulting emissions typically gen-
erated during this operation.
Project Plan
Six tasks were performed during the
project. Each was designed to produce
vital elements and data for a future pilot
scale unit. The six tasks were to:
O Establish a fully operational, labora-
tory scale vapor-phase lubricant
delivery system (LDS).
O Formulate lubricants and evaluate
the lubricity of the vapor-deposited
polymers using the ring compression
test.
O Forge parts using conventional
lubricants to provide baseline data.
O Modify the forging die to permit
vapor-phase lubrication.
O Forge five parts using vapor-phase
lubrication in a modified die.
O Quantitatively compare the emis-
sions from vapor-deposited lubrica-
tion with those from the convention-
al oil-based lubrication system.
-------
Emission Results
The volume of lubricant used during
each experiment was determined qualita-
tively by the metal flow and release pro-
perties exhibited by each technique. Metal
flow is defined by the interface friction
factor (m value) which is a measure of
metal flow within the die. Release pro-
perties are defined by the relative ease
with which the part can be removed from
the die. It was assumed that all lubricant
used during each experiment was vola-
tilized to the atmosphere. This represents
the worst case scenario for the process.
Table 1 summarizes the results.
Conclusion
Although this project included a limited
number of experiments, it did show that
vapor-phase lubrication is feasible for
metal forging. It can also result in a
significant reduction of potential emis-
sions to the atmosphere. The process
could reduce emissions from forging and
casting operations by as much as 85%.
The project represents only the first
step, laboratory feasibility, of the develop-
ment program for vapor-phase lubrication.
Significant research and development still
remains, including die lubrication system
design and lubricant formulation
development.
Table 1. Average Emissions and Forging Parameters
Average block and finish per part, ml
Average forging force, ton (kNj
Average forging time, sec
Conventional
Lubrication
76
75 (667)
60
Vapor-Phase
Lubrication
11.3
75 (667)
60
J. J. Mills is with Martin Marietta Laboratories, Baltimore, MD 21227.
Charles H. Darvin is the EPA Project Officer (see below).
The complete report, entitled "Novel Vapor-Deposited Lubricants for Metal-
Forming Processes," (Order No. PB 87-227 351 /AS; Cost: $11.95. subject
to change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield. VA 22161
Telephone: 703-487-4650
The EPA Officer can be contacted at:
Air and Energy Engineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park. NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
Official Business
Penalty for Private Use $300
EPA/600/S2-87/060
------- |